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Fuels procurement and costs have been weighing on the minds of Indian cement producers since the start of the Russian invasion of Ukraine in February 2022. Two news stories this week show some of this. The first concerns recent imports of petcoke from Venezuela. The second covers the closure of captive power plants due to domestic shortages of coal.

At the same time, as the financial results for cement companies for the first quarter of the Indian 2023 financial year have been released, one constant has been hefty hikes in power and fuel costs. Graph 1 below gives a rough idea of the jump in costs major producers have been contending with. One point to note is that, possibly, the larger cement companies may have been better at slowing down the cost inflation from fuel. However, the prevalence of waste heat recovery installations and alternative fuels usage may also be a factor here. Finally, the company approved to buy Ambuja Cement and ACC, Adani Group, also runs India’s biggest coal trader. It will be interesting to see in the medium term how this might affect the fuel costs for its new cement division.

Graph 1: Comparison of Power & Fuel costs for selected Indian cement producers in first quarter of 2022 and 2023 financial years. Source: Company financial reports.

The Venezuelan story demonstrates the greater lengths that Indian cement producers are now going to secure fuel supplies. Reuters reports that cement companies imported at least 160,000t of petcoke from the South American country between April and June 2022 and that more was on the way. JSW Cement, Ramco Cements and Orient Cement are among them. The Venezuelan oil industry has been under US economic sanctions since 2019 but byproducts such as petcoke are not covered by this. Its petcoke has apparently been discounted by 5 - 10% below the price of US alternatives.

Indian cement producers have been prepared to risk US sanctions further by importing coal from Russia. The Business Standard newspaper, using data from Coalmint, reported that Russia became India’s third largest source of coal imports, at 2.06Mt, in July 2022. Before the war it was the sixth-largest source of coal to the country. Again, Reuters covered how cement companies were doing this in July 2022, when it revealed that UltraTech Cement had used India-based HDFC Bank to purchase coal using Chinese Renminbi, not the US Dollar as is more common for international purchases of commodities. In a conference call for the release of its first quarter results, UltraTech Cement’s chief financial officer Atul Daga confirmed the purchase and described it as “opportunistic.” He added that, “If something more surfaces, we will pick it up.” As the data for July 2022 shows, it may or may not be UltraTech Cement that is buying Russian coal right now but other parties in India certainly are.

Some of the wider economic implications about India buying Russian coal in the face of US and European sanctions include whether any retaliation might be forthcoming and a general sign that the dominance of the US Dollar as the world’s reserve currency is not guaranteed. The former seems doubtful given the size of India’s markets. Yet if the sanctions against Russia drag on then a shift in the global economic status quo becomes more likely, especially if opportunistic purchases become regular ones.

The situation facing captive power plants illustrates one more turn of the screw on energy costs for industrial manufacturers. 30% of captive power plants in India are reportedly closed due to the high cost of coal or an inability to even import it. Although it is worth noting that it is unclear whether, proportionally, more or less of these are serving cement plants. As N Srinivasan, the vice-chairman and managing director of India Cements told the Business Standard newspaper, “Most of our plants have coal based captive power generation. The cost of captive generation is now more than the grid cost. Hence, we shut down all captive power units and resorted to grid power.”

The International Energy Agency (IEA) forecast in July 2022 that Indian coal demand would grow by 3% year-on-year to 1.16Bnt in 2023 due to expanded electrification and economic growth. In its view, global coal demand will be driven principally by China but also by India to a lesser extent. However, unhelpfully, it added that uncertainty was also rising with ongoing developments in the war in Ukraine having a prominent effect. This is unlikely to assist Indian cement producers and their fuel buyers who will be asking themselves: how long will the current situation last and can the prices be passed on to consumers? There is one small silver lining in the current group of economic storm clouds hanging over cement producers at least. The second quarter of the Indian financial year is monsoon season, when economic activity slows down. It won’t slow the trend down but it may reduce the fuel bill a little.

Saudi Arabia: Al Jouf Cement has appointed Abdul Karim bin Muhammad Al Nuhair as its chief executive officer. He succeeds Jamal bin Salem Al Amer in the post who has resigned for personal reasons. Al Amer has now been appointed as president ex-executive advisor to the company.

Al-Nuhair holds a bachelor’s degree in Industrial Management and a master’s of Executive Directors from King Fahd University of Petroleum and Minerals. He holds both management and board-level experience in a number of private and public companies.

Oman: Raysut Cement has appointed Khalid Ramis Mohammed Al Rawas as its chief executive officer. It follows the resignation of Ghose Jotirmoy Pratul Krishna in early August 2022. Al Rawas holds nearly 30 years of experience working in the banking sector. He joined Raysut Cement in 2019.

Taiwan: An-Ping Chan has become the president of Taiwan Cement in addition to his current roles as the group’s chief executive officer and the company’s chair. The concurrent appointment follows the resignation of previous president Jong-Peir Li due to personal health reasons.

New Zealand: Fletcher Building Materials recorded consolidated sales of US$5.37bn during its 2022 financial year, up by 4.7% year-on-year from US$5.13bn in the previous year. Its net earnings also rose by 42%, to US$273m from US$193m.

The group's concrete division, which includes Golden Bay Cement, contributed US$556m-worth (9%) of group sales. The figure represents an 8% increase from 2021 financial year levels. The business recorded 'strong performances' across all key product segments, underpinned by 'robust' demand and pricing. It made capital expenditure investments of US$51.1m, including in a waste tyre recycling system upgrade at the Golden Bay cement plant. The latter increased the plant's alternative fuel (AF) substitution to 50% from 35%. The company also continued to focus on developing low-CO₂ concrete binders.

Fletcher Building Materials chief executive officer Ross Taylor said "The 2022 financial year has not been without its challenges. Global and national supply chain disruptions have continued into the third year of the Covid-19 pandemic." He added "The New Zealand Commerce Commission recently published its interim market study report into residential building supplies. The final report and recommendations will be published in December 2022 and in the meantime we will continue to work collaboratively with both the commission and the government."

Turkey: KÇS Kipaş Çimento has placed an order with KHD Humboldt Wedag for a Pyrorotor for its Kahramanmaraş cement plant. The supplier says that the equipment will enable the plant's calciner to achieve an alternative fuel (AF) substitution rate of 90%. It will additionally restrict NO_x emissions to 800mg/Nm³. After a short shutdown for assemblage of gas duct connections, KHD expects to commission the upgraded system in mid-to-late 2023.

The company says that the KÇS Kipaş Çimento contract represents its 11th Pyrorotor order globally and the first in Turkey.

Czech Republic: Lafarge Cement says that it has achieved an alternative fuel (AF) thermal substitution rate of 95% at its Čížkovice cement plant. The plant's fuel mix includes contaminant fractions from local plastic recycling. As a result of the move, the plant no longer uses any natural gas in its cement production.

In 2022 as a whole, the producer plans to increase its share of reduced-CO2 cement sales, increase construction waste recycling in its products and reduce its cement's water consumption.

Australia: James Hardie has informed investors that it has frozen all non-critical hiring. The Australian newspaper has reported that the move is designed to counteract the impacts of a rise in costs. The company also plans to announce a new round of price rises on its products.

Tajikistan: Cement production fell by 7% year-on-year to 2Mt in the first half of 2022 from 2.16Mt in the same period in 2021. The Avesta News Agency reports no reason for the decline but it noted that the construction sector had grown so far in 2022. The country’s cement industry exports around 1.5Mt/yr to neighbouring countries including Afghanistan, Uzbekistan and Kyrgyzstan.

Afghanistan: Ghori Cement has restarted production at its Baghlan plants near Pul-e-Khumr in Baghlan province after a stoppage of four months. Production halted at the units due to the high price of coal, according to Pajhwok Afghan News. The government is now supplying coal to the plants at a pre-agreed price. Other local news sources report that production has increased to 520t/day from 350t/day previously, following work on a variety of technical issues.